Electronic control system



Oct. 19, 1948. .LL H. WYMAN 2,451,893

' ELECTRONIC CONTROL SYSTEM Filed Oct. 26, 1945 I III] INVENTOR. JOHN H. WYMAN,

Patented Oct. 19, 1948 UNITED STATES PATENT OFFICE ELECTRONIC CONTROL SYSTEM Application October 26, 1945, Serial No. 624,823

8 Claims. 1

The present invention relates to electrical control systems and, particularly, to such systems for controlling the translation of power from an alternating current power-supply source to a power load. While not limited thereto, the invention has particular utility in electrical resistance spotwelding systems, and will be described in that connection.

In electrical resistance spot-welding systems, it is frequently desirable to provide a control system by which to control the amount of power supplied during each spot-welding operation. Depending upon the particular type oi spot weld desired, such control systems may control one or more conditions which determine the character of the weld. For example, the system may control the magnitude of a Welding current or a rate of change of magnitude during each welding interval. One characteristic in common with all such control systems is that they control, during each spot-welding operation, the period during which current flows to the weld. This furnishes a primary control over the power supplied to the weld and thus determines in large part the character of the weld obtained. If the control system is to have utility in a wide range of applications involving numerous types of materials to be welded, or if it is to be easily and readily adjusted to obtain a particular character of weld in a particular material, it is usually necessary that provision be made for easily adjusting the control system accurately to obtain a desired time interval for each welding operation.

Numerous control systems have heretofore been proposed by which to provide a desired interval of current flow for each welding operation. Where accuracy of timing of the welding interval is paramount, as is usually the case, these prior control systems tend to become more and more complicated, more expensive, and less easily adjustable to select a desired time interval.

It is an object of the present invention, therefore, to provide a new and improved control system for controlling the translation of power from an alternating current power-supply source to a power load and one which avoids one or more of the disadvantages and limitations of prior such control systems.

It is an additional object of the invention to provide a new and improved control system, for controlling the translation of power from an alternating current power-supply source to a power load, of relatively simple and inexpensive construction.

It is a further object of the invention to provide a new and improved control system, for controlling the translation of power from an alternating current power-supply source to a power load, which is characterized by an unusually high degree of accuracy in effecting a desired time interval of translation of power from the source to the load.

In accordance with a particular form of the invention, a control system, for controlling the translation of power from an alternating current power-supply source to a power load, comprises a gas-discharge device having an anode and a cathode serially included between the source and the load and adapted to control the translation of power from the source to the load. The system includes an energy-storage means, a unidirectional energizing circuit responsive to the potential drop across the anode and cathode for causing energy from the source to be stored in the energy-storage means during an interval when the device permits no power to be translated from the source to the load, means for conditioning the device .to permit power to be translated from the source to the load, and means for discharging energy from the energy-storage means during the interval when the device permits power to be translated from the source to the load. The control system also includes means operative upon the discharge of the energy to a predetermined value for controlling the device to terminate the translation of energy through the device from the source to the load For a better understanding of the present invention, together with other and further objects thereof reference is had to the following description taken in connection with the accompanying drawing, and its scope will he pointed out'in the appended claims.

Referring now to the drawing, the single figure thereof is a circuit diagram representing a complete electrical resistance welding system which includes a control system embodying the present invention.

This control system is utilized to control the translation of power from an alternating current power-supply source ID to a power load i l shown as a resistance welder. The welder includes a pair of conventional welding electrodes l2, l3 which is connected to individual terminals of a secondary winding [4 of a welding transformer Hi. The transformer i5 is a conventional transformer used for welding purposes and includes a primary winding l6 having one terminal connected to the alternating current source ID and the other terminal connected to the source through a pair of oppositely poled gas-discharge devices 17, [8. The input circuit of the gas-discharge device I? includes in series relation a current limiting resistor 59, the secondary winding 28 of a transformer El and the secondary winding 22 of a transformer 23. The transformer 2i has a primary winding 24 coupled across the powersupply source It and its secondary winding 2'!) develops a voltage of such magnitude and phase as normally to maintain the gas-discharge device ll in a nonconductive state. The transformer 2.3 has a primary winding 25 connected across the primary winding it of the transformer H 5 and is of such construction that the voltage developed in its secondary winding 22 has a larger magnitude than that of the secondary winding 20 of the transformer 2i and a phase such as to render the gas-discharge device l1 conductive.

The control system includes an energy-stop age means, coprising a condenser 21, and a unidirectional energizin circuit responsive to the potential drop across the anode and cathode of the gas-discharge devices l1 and i3 for causing energy from the source M3 to be stored in the condenser 21 during an interval in which the gasdischarge devices permit no power to be translated from the source H3 to the load l I. In particular, this energizing circuit is coupled across the anodes and cathodes of the gas-discharge devices l1 and i3 and includes a unidirectional conductive device or rectifier 28. The unidirectional circuit may be traced from the cathode of the gas-discharge device H and the anode of the device l8 through a conductor 28, the normally closed contacts 29 of a relay 3B, the rectifier device 23, the condenser 21, and a conductor 31 to the anode of the gas-discharge device I! and cathode of the device l8.

The control system additionally includes means for conditioning the as-discharge devices I! and 18 to render them conductive and thereby permit power to be translated from the source to the load II. This means comprises a transformer 32 having a primary winding 33 energized from the power-supply source H3 and having a secondary winding 34 which develops a peaked voltage at the beginning of each cycle of the source It]. The secondary winding 36 is normally shorted through a pair of normally closed contacts 35 of the relay 36 and a current limitin resistor 35 but is arranged, upon opening of the relay contacts 35, to be included in the input or control circuit of the gas-discharge device l8. The latter circuit includes a current limiting resistor 38, the secondary winding 39 of a transformer 4!], the secondary winding 34 of the transformer 32, the resistor 36, and a resistor 4| which has connected in shunt thereto acondenser 42. The transformer 45] is similar to the transformer 2!, used with the gas-discharge device l1, and includes a primary winding 43 which is energized from the power-supply source if). The voltage developed in the secondary winding 39 of the transformer All has such magnitude and phase as normally to maintain the gas-discharge device l8 in the nonconductive state. The conditioning means also includes the relay 3!! which has an operating Winding 44 connected across the powersupply source ill through a pair of normally open contacts 45 of a manual push button 16.

There is provided in the control system means for discharging energy from the condenser 21 during the interval when the gas-discharge devices I"! and it are conductive and permit power to be translated from the source H3 tic-the load I I. This means comprises an adjustable resistor 41 connected across the condenser 21 to provide therewith a predetermined time constant which establishes the welding interval or interval of conductivity of the gas-discharge devices l7 and I8.

There is also provided means operative upon the" discharge of the condenser 21 to a predetermined value for controlling the gas-discharge device l8 to terminate the translation of energy through the latter device from the source H! to the load I! This means includes a gas-discharge device 48, normally nonconductive, having input electrodes coupled across the condenser 2'5 and having an output-circuit load impedance comprising the resistor 41 and condenser 42 included,

as previously mentioned, in a control circuit of the gas-discharge device 18 for rendering the latter device nonconductive during the interval when the discharge device 48 is conductive. The last-mentionedmeans also includes means for causing the gas-discharge device 68 to become conductive upon the discharge of the energy --of the condenser 2'! to the aforementioned predetermined value, this means comprising a transformer 49 having a primary winding 58 energized from the power-supply source and having-a secondary winding 5! serially included with the condenser .21 in the input circuit of the discharge device to, The secondary winding 5% of the transformer 49 develops a potential of magnitude less than the fully charged potential of the condenser 21 yet of such magnitude and phase as to render the discharge device 48 conductive upon discharge of the condenser 21 to theaforementioned predetermined value. p

A transformer 52- has a primary Winding 53 energized from the power-supply source I8 and includes a secondary winding M which applies a suitable operating potential to the anode of the gas-discharge device 48. The output circuit of the latter includes means responsive to the operation. of the discharge device 48, in efiecting the termination of power translation from the source H) to the load 5 l, for cleenergizing the unidirectional energizing circuit of the condenser 21 to prevent any additional storage of energy in the condenser 21 during the operative interval of the discharge device Mt This means comprisesa relay 55 having an operating winding 55 included in the output circuit of the discharge device 48 and having a pair of normally closed contacts 5'! connected in parallel with the normally closed contacts 29 of the relay 3!].

Considering now the operation of the control system just described, assume as an initial condition that the manually operable switch 45 is in open-circuit position so that therelay is de-energized and its contacts 29 and are closed. Under this assumed condition-of operation, the only potential applied between the input or control electrodes of the gas-discharge device [8 is that provided by the secondary winding 39 of the transformer ll). As earlier mentioned, this potential has such magnitude and phase that it maintains the discharge device iii in its nonconductive state. With the discharge device it nonconductive, no current flows from the powersupply source IE! through the primary winding [6 of the welding transformer 15 so that the transformer 23 remains de-energized. The only potential thus appearing in the input or control circuit of the gas-discharge device I1 is that of the secondary winding 29 of the transformer 21, but this potential also has such magnitude and phase as to maintain the discharge device I! in its nonconductive state. No power is thus supplied to the Welding electrodes I2 and I3, At the same time, the full potential of the power-supply source I appears across the anodes and cathodes of the discharge devices I1 and I8 and the condenser 2'! is thus charged through the rectifier device 28 substantially to the peak potential of the power source Ill. The unidirectional energizing or charging circuit for the condenser 21 includes the conductor 26, the normally closed contacts 29 of the relay 30 or the normally closed contacts 51 of the relay 55, the rectifier device 28, and the conductor 3|, as previously described. The negative potential developed across the condenser 2! when the latter is fully charged is much larger than the potential developed in the secondary winding 5| of the transformer 49 and thus maintains the discharge device 48 in its nonconductive state. The relay 55 is then deenergized with its contacts 5'! closed.

Assume now that the manual push button 46 is operated to close its contacts 45, thereby to energize the relay which in operating opens its contacts 29 and 35. Opening of the relay contacts 29 does not interrupt the charging circuit of the condenser 21 since this circuit remains completed through the normally closed contacts 51 of the relay 55. However, opening of the contacts of the relay 3!! places the secondary winding 34 of the transformer 32 in the input or control circuit of the gas-discharge device I8. The peaked voltage developed in the secondary winding 34 has a magnitude larger than that developed in the secondary winding 39 of the transformer and is effective to render the gas-discharge device I8 conductive. Since the peaked voltage of the secondary winding 34 of the transformer 32 occurs at the beginning of a cycle of the power-supply source I 0, the gas-discharge dewelding electrodes I2 and I3. At the same time,

the potential appearing across the primary winding I6 of the welding transformer l5 energizes the transformer 23 which develops in its secondary winding 22 a voltage of such magnitude and phase as to overcome the holding voltage of the transformer 2| and cause the gas-discharge device I! to become conductive during the succeeding half cycle of the source I 0. The gas-discharge devices I! and I8 thus alternately conduct successive half cycles of the source I 0 until such time as the gasdischarge device I8 is rendered nonconductive by the control system in a manner now to be described.

As soon as the gas-discharge devices I1 and I8 become conductive as described, the potential drop across their anodes and cathodes drops to a very low value, for example of the order of twelve volts, as is well known. Thus while the charging circuit of the condenser 21 is maintained through the normally closed contacts 5! of the relay 55 even after the contacts 29 of the relay 30 have opened, the potential drop across the condenser 21 due to its charge is much larger than that occurring across the anodes and cathodes of the gas-discharge devices I! and I8 so that the condenser no longer receives any additional charge and begins to discharge through the resistor 47. The rapidity with which the condenser 21 discharges is dependent, of course, upon the adjusted value of the resistor 41. When the energy of the condenser 21 has discharged to a predetermined value at which the potential across the condenser has a value less than that of the potential developed in the secondary winding 5| of the transformer 49, the latter potential causes the discharge device 48 to become conductive. The space current of the discharge device 48 flows through the cathode resistor 4| to develop thereacross a potential of magnitude larger than the peaking potential developed in the secondary winding 34 of the transformer 32. The potential developed across the resistor 4| appears, as previously described, in the input or control circuit of gas-discharge device I8 so that the latter is thereupon rendered nonconductive. This removes the energization from the transformer 23 and causes the gas-discharge device I! also to be rendered nonconductive at the end of the half cycle following the last half cycle during which the discharge device I8 was conductive. The translation of energy from the power source I0 through the discharge devices I! and I8 to the load II is thus terminated.

As soon as the gas-discharge device 48 is rendered conductive, the relay 55 is energized to open its contacts 51. Assuming that the push button remains closed to maintain the relay 30 energized. the opening of the contacts 51 of the relay interrupts the charging circuit of the condenser 27. Thus, while the full voltage of the power-supply source I!) again appears across the anodes and cathodes of the gas-discharge devices I! and I8 upon the latter becoming nonconductive, the condenser 21 is not again recharged. This is because the continued energization of the rela 30 maintains its contacts 29 open and the gas-discharge tube 48 remains conductive to maintain the relay 55 energized with its contacts 51 open. The relay 55 is a fast-operating one, its operation being suillciently rapid that little or no charge is received by the condenser 21 after the devices I! and I8 are rendered nonconductive and before the relay contacts 51 open. A complete welding operation is thus completed and the gas-discharging devices I1 and I8 thereafter remain in their nonconductive state until the control system is reset to condition the system for a subsequent welding operation. Resetting of the system is accomplished by o ening the push button 46 to de-energize the relay 30. The latter thereupon closes its contacts 29 and 35 to remove from the input or control circuit of the gas-discharge device I8 and the peaked voltage of the transformer 32 and to complete the unidirectional energizing or charging c rcuit of the condenser 27. The condenser 21 quickly recharges again to the voltage of the power-supply source In and. upon bein recharged. causes the discharge device 48 to become nonconductive. This removes the potential developed across the resistor 4| and causes the relay 55 to become deenergized to close its contacts 51. The control system is thereupon reset and ready to start a subsequent cycle of the welding operation described.

It will be apparent from the foregoing description of the system operation that the number of complete cycles of the power source I0. during which the discharge devices I? and I8 are conductive, is dependent upon the time required for the condenser 2! to discharge through the resistor 41 to a predetermined value at which the discharge device 48 becomes conductive. This "77 ltimefintenvalzmay becontrolledrby adjustment -of :the *value :of the resistor s41 and'nnay lbe readily Established rat any desired :vetlue drom -one comrplete-"oycle to a :laundred i or more -:complete cycles;

iFrom ithe :ioregoing {description of the inven- -tion,, it will :be :apparent that the relay 30 comparises imeans operative subsequently to the $91 animation of energy translation -irom :the -.source All through the discharge devices 1-?! and 4B to the powenloadM ifor'de-eenergizing themonditiom ting means comprising the transformer 32, name- ;-1-y by closure of :the relay lcontaots-35, (and .-f.or reflecting the f restoration of the energy storage in .the condenser 121., namely by completion .of the ,ccharging-circuit upon closure of xits contacts 29,

=tolcondition the control system for anothercycle .01? control operation.

While *not Ylimited thereto but simply illustraltive as 'a specific embodiment of the invention, "the iollowing circuit econstants are vgiven ior an embodiment of the invention of the type shown .dn gthe isingle .figure .of the drawing;

Dischargeidev'ices I and ML.-- Type CBJ Discharge 'd-evice 4'3 TypeiZOBO Rectifier 28 Type-8O Transformers 2 1 and :40, secondiary -pot'ential 'lll volts "Transformer :23, secondary portential '50vo1ts Transformer 32, secondary peak" red'potentialtR. M. so T24votes (Transformer 43, secondary poftentia-l lflvolts Resistors Hand 3-8 "lflflilohms Resistor 36-"; 1000 ohms .Resistor '4 I 12500'ohms Resistor 4"! "Maximum :280;000'ohms *Minimum i l0g000iohms Gondenser 2 0.5 imicrofarads *Gondenserdi 2:0zmicro'farad s .Relay fid ra pidity 'o'f operati'oi'nte -second :Potential of source 11] 220vo1ts Number 'of complete cycles of conductivity of discharge Jdewices 1 'and :18 :for :minimum and maximum values 10f :resis- *t'orfll: I

-M'mi'mum l'cycle iliaxrmum -2'8cyc1es 'Nhilethere has been describedwha't is at present considered to be the preferred embodiment o'fthis invention, it will-be obvious to those skilled inthe art that various changes and modifications "may be made therein without departing from "the "invention, and it is, therefore, aimed "to'cove'r -powe1'""from said source to said load, energystorage means, a unidirectional energizingrir- -cu'it responsive to the potential drop across said anode and :cathode for causing energy from said source to be's'tored'in said energy-storage means during an interval when said device permits no power ito be translated from said source to said load, means for conditioning said device to perm'it power to =be translated from said "source to load, :means ifor discharging -ene17gy"'trom said energy-storage'imeans during the interval when said device :permits .power -to be translated iromzsaid sourcetosaid load, and means "operative upon the discharge -.of said energy :to =a ,pre-

determined. xvalue rfor' controlling said device to terminate the translation of energy ithroughisaid device from saidsourcezto saidioad.

2. Acontrolsystem for controlling the ttr-anslationaof :power :fromian .alternatingcurrent mowersupply source :to a power load comprising, a gasidischarge :device having an-an'ode aand a cathode serially :included ibetween said source and :said load and adapted to control the translation -of power from said-source to said lead, energy-storage means, :an energizing circuit coupled across .sai'danode and-cathode and including a unidirec- :tronal conductive device for storing energy rilrom (said source in said energy-storage means during an interval when said firstementionedidevice per- .mits no power to the translated-from said source to said loadnneans TfOI conditioning said first device to permit power to be translated from said source to said load,ameans for di-schargingenergy from saidenergy-storage =meansduring the interval when rsaidefirst device ipermits power to he =-tr-anslated :from said source to said load, and means operative upon the discharge 'ofisaid energy to .a predetermined value ior-controllingsaid first device to terminate .the translation of energy through said first device :from :said source tosaid load. -3. A control system for controlling the translationof power .from antalternatingcurrentpowersupplysource to a power:1oad--.comprising,:a gasdischarge device having'an anode and acatlmde serially included .between said source 'and .said load and -=adapted to control the translation 10f power fromsaid source to saidloai -a condenser, a unidirectional energizing circuit responsive to the potential dro acrossrsaidanodaand icathode if or causing energy from said source to Joe :stored in said condenser during .an interval when said device permits no power to .be translated .Irom said .source to vsaid load, means for conditioningsaid device to permit power .to be translated from said source to said load, means ,providin with said condenser a predetermined time constant for discharging energyfrom said condenser during .the interval when said device .permits ,power to be translated from said source .to said load, and means operative upon .the discharge of said energy .to a predetermined value .for controlling said device to terminate the translation of energy vthrough said device .from said source to saidvload.

.4. Acontrol-system for controlling the translationof power :fromanalternatinglcurrent power- .supplysource to a powerload comprisingagasrclischargedevice having an anode and a cathode serially included between said source and :said load and adapted to control -.the translation of power from said source to said :load, a condenser, a unidirectional energizing circuit "responsive ?to the potential drop across said ianodeand cathode for causing energy lfrom said source i130 be stored in said condenser during interval when .said device permits no :powerto be translated from said source to .said :load, means for conditioning said device to :permit power to be translated -from?said:source-to said zl'oad,-.an adjustable resistor coupled across said condenser for discharging energy from said condenser during the interval when said device permits power to she translated :from said source to said Head, and :means operative upon 'the discharge of said energy to a predetermined value for controlling said device to terminate the translation of energy through said device from said source to said load.

5. A control system for controlling the translation of power from an alternating current powersupply source to a power load comprising, a gasdischarge device having an anode and a cathode serially included between said source and said load and adapted to control the translation of power from said source to said load, energy-storage means, a unidirectional energizing circuit responsive to the potential drop across said anode and cathode for causing energy from said source to be stored in said energy-storage means during an interval when said device permits no power to be translated from said source to said load, means for conditioning said device to permit power to be translated from said source to said load, means for discharging energy from said energy-storage means during the interval when said device permits power to be translated from said source to said load, means operative upon the discharge of said energy to a predetermined value for controlling said device to terminate the translation of energy through said device irom said source to said load, and means responsive to the operation of said last-mentioned means in effecting said termination of power translation for de-energizing said unidirectional energizing circuit to prevent during the operative interval of said last-mentioned means any additional storage of energy in said energy-storage means.

6. A control system for controlling the translation of power from an alternating current powersupply source to a power load comprising, a gasdischarge device having an anode and a cathode serially included between said source and said load and adapted to control the translation of power from said source to said load, energy-storage means, a unidirectional energizing circuit responsive to the potential drop across said anode and cathode for causing energy from said source to be stored in said energy-storage means during an interval when said device permits no power to be translated from said source to said load, means for conditioning said device to permit power to be translated from said source to said load, means for discharging energy from said enorgy-storage means during the interval when said device permits power to be translated from said source to said load, and means including a second gas-discharge device having input electrodes coupled across said energy-storage means and operative upon the discharge of said energy to a predetermined value for controlling said first-mentioned device to terminate the translation of energy through said first-mentioned device from said source to said load.

'7. A control system for controlling the translation of power from an alternating current powersupply source to a power load comprising, a first gas-discharge device having an anode and a cathode serially included between said source and said load and adapted to translate power from said source to said load during an interval when said device is conductive, energy-storage means, a unidirectional energizing circuit responsive to the potential drop across said anode and cathode for cau ing energy from said source to be stored in said energy-storage means during an interval when said device permits no power to be translated from said source to said load, means for rendering said device conductive to permit power to be translated from said source to said load, means for discharging energy from said energystorage means during the interval when said device permits power to be translated from said source to said load, a second gas-discharge device normally nonconductive and having an output circuit load impedance included in a control circuit of said first device for rendering said first device nonconductive during the interval when said second device is co:-: iuctive, and means for causing said second device to become conductive upon the discharge of said energy to a predetermined value to render said first device nonconductive and terminate the translation of energy through said first device from said source to said load.

8. A control system for controlling the translation of power from an alternating current power supply source to a power load comprising, a gas-discharge device having an anode and a cathode serially included between said source and said load and adapted to control the translation of power from said source to said load, energystorage means, a unidirectional energizing circuit responsive to the potential drop across said anode and cathode for causing energy from said source to be stored in said energyst-orage means during an interval when said device permits no power to be translated from said source to said load, means for conditioning said device to permit power to be translated from said source to said load, means for discharging energy from said energy-storage means during the interval when said device permits power to be translated from said source to said load, means operative upon the discharge of said energy to a predetermined value for controlling said device to terminate the translation of energy through said device from said source to said load, and means operative subsequently to said termination of energy translation for de-energizing said conditioning means and for effecting the restoration of the energy storage in said energy-storage means to condition said control system for another cycle of control operation.

JOHN H. W YMAN.

REFERENCES CITED UNITED STATES PATENTS Name Date Faulk Nov. 20, 1945 Number 

